Dynamic support for an article of foot wear

ABSTRACT

A support for an article of foot wear including a dynamic support that is capable of molding to a portion of a plantar surface of a foot. The dynamic support includes a plurality of independently movable particles.

CROSS-REFERENCED APPLICATION

This application claims the benefit of U.S. Provisional Application Ser.No. 61/614,788, filed on Mar. 23, 2012, which is incorporated herein byreference in its entirety.

BACKGROUND

1. Field of the Disclosure

This disclosure relates to a support for a shoe that is able to providecustomized and continued support to the heel and one or more of thearches of the foot of the wearer. More particularly, the presentdisclosure relates to a support that is disposed inside of a shoe thatis able to provide support to a portion of the foot using both a staticsupport shell with a dynamic support component.

2. Description of the Related Art

In the prior art there are various known methods for capturing andsupporting the contours of the foot of a wearer, however, aninexpensive, uncomplicated, clean, and accurate methodology fordynamically providing support to the arches and heel of the foot and, inparticular, to the medial arch and lateral of the foot of a wearer, doesnot exist.

Therefore, there exists a need in many applications and contexts, suchas but not limited to, the fields of customized foot supports, footwearand the like, for a dynamic support or an article containing a dynamicsupport that provides customized support for the plantar surface of thefoot.

SUMMARY

The present disclosure provides for a dynamic support that is disposedbeneath the heel of a wearer that is moldable by the underside of thefoot to provide at least partial support to at least one of the medialarch, lateral arch, transverse and metatarsal arch and heel of the footof a wearer.

The present disclosure provides for a customized insole that contains adynamic member that is able to adjust to the contour of a heel and to atleast a portion of an arch of a wearer of such insole.

The present disclosure provides for a customized insole that contains acontoured support and a dynamic support that together provide forcustomized arch support of the heel and at least one arch of the foot ofthe wearer.

The present disclosure provides for a midsole that includes a dynamicsupport that is moldable by the underside of the foot to provide atleast partial support to one of the arches of the foot of a wearer.

The present disclosure provides a support shell that is molded tosupport the arches of the foot of a wearer; in particular, the lateralarch, the metatarsal arch, the medial arch and the lateral arch of the afoot of a wearer.

Another embodiment includes a resilient spacer disposed between the basesupport shell or built-in portion of the shoe and the dynamic support inthe heel portion.

Still yet another embodiment includes a support for an article of footwear comprising: a dynamic support that is capable of molding a portionof a plantar surface of a foot, wherein the dynamic support comprises afluid material combined with a lubricity enhancer. The fluid material isa highly viscous fluid material comprising silicone. The lubricityenhancer is at least one material selected from the group consisting of:polytetrafluoroethylene (PTFE) and grease.

A further embodiment includes a support for an article of foot wearcomprising: a dynamic support that is capable of molding a portion of aplantar surface of a foot, wherein the dynamic support comprises aU-shaped member and either a gas or a fluid disposed therein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a illustrates a dynamic support according to the presentdisclosure;

FIG. 1 b illustrates an insole for placement in an article of footwearhaving a dynamic support, according to the present disclosure;

FIG. 1 c illustrates an insole with a dynamic support in the heelregion;

FIG. 2 illustrates a top view of a base support shell with dynamicsupport according to the present disclosure;

FIG. 3 illustrates a cross-section view of base support shell anddynamic support of FIG. 2 taken along line 3-3;

FIG. 4 illustrates a cross-section of a package for holding particles ofdynamic support;

FIG. 4A illustrates a cross-section of a package for holding particlesof dynamic support similar to FIG. 4, above, but also including aresilient spacer disposed under the dynamic particle support in the heelregion according to another embodiment of present disclosure;

FIG. 5 illustrates a dynamic support according to the presentdisclosure;

FIG. 6 illustrates a second top view of a base support shell withdynamic support according to the present disclosure;

FIG. 7 illustrates a perspective view of the base support shell takenfrom the medial side;

FIG. 8 illustrates a perspective view of the base support shell takenfrom the lateral side;

FIG. 9 illustrates a further perspective view of the base support shelltaken from the medial side;

FIG. 10 a illustrates a bottom view of a base support shell according tothe present disclosure;

FIG. 10 b illustrates a side view of a base support shell having asupport element;

FIG. 10 c illustrates a rear view of base support shell having a supportelement;

FIG. 10 d illustrates a medial side of base support shell having supportelements and stiffening support structure;

FIG. 11 illustrates components of a first embodiment of the insole of inan unassembled configuration, according to the present disclosure;

FIG. 12 illustrates a base support shell, according to a secondembodiment of the insole of the present disclosure;

FIG. 13 illustrates a base support shell, according to a thirdembodiment of the insole of the present disclosure;

FIG. 14 illustrates an insole in an unassembled configuration withdynamic support and liner, according to a second embodiment of theinsole according to the present disclosure;

FIG. 15 illustrates an insole in an unassembled configuration withdynamic support and liner, according to a third embodiment of the insoleaccording to the present disclosure;

FIG. 16 illustrates an insole with a secondary dynamic particle support;

FIG. 16A illustrates an insole with a secondary dynamic support whichalso includes a resilient spacer disposed under the dynamic particlesupport in the heel region according to another embodiment of presentdisclosure;

FIG. 17 illustrates an exploded view of the insole of FIG. 16;

FIG. 17A illustrates an exploded view of the insole of FIG. 16A with theresilient spacer;

FIG. 18 illustrates a further embodiment of the insole according to thepresent disclosure having an additional permeable medium layer overdynamic component and/or particles;

FIG. 19 illustrates a midsole for a shoe;

FIGS. 20 a and 20 b Illustrate a midsole for an athletic shoe; and

FIGS. 21 a through 21 c illustrate the dynamic support of the presentdisclosure incorporated into a brace.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings and in particular to FIG. 1 a, a dynamicsupport is shown and referenced by reference numeral 150. Dynamicsupport 150 is a moldable member that deforms and retains the shape of aheel of a wearer and a portion of at least one of the lateral, medial,metatarsal or transverse arch of a foot during wear in a shoe of awearer. Dynamic support 150 has a U-shaped configuration and is disposedunder the heel of the wearer of a shoe. Dynamic support 150 has two arms8 that are either connected to each other or connected with a base 6.Dynamic support 150 is made from materials that permit such dynamicsupport. Such materials conform to and simultaneously support the heelof the wearer. Dynamic support 150 is configured to support a portion ofat least one of the lateral, medial, metatarsal and/or transverse archof the wearer.

While dynamic support 150 is shown as having a U-shaped configurationdynamic support may also have the shape of a torus or an ovoid. Dynamicsupport 150 may have asymmetrical shapes to add support to medial and/orlateral arches.

Dynamic support 150 may be inserted into an article of footwear beneatha heel to provide dynamic support to the medial arch and lateral arch,and in particular, the posterior portion of the medial and lateral arch.Accordingly, dynamic support 150 may be inserted inside of a shoe.

Alternatively, as shown in FIG. 1 b, dynamic component 150 can be usedwith a base support shell 50, as described in greater detail below, toform an insole 10 with specifically customized heel and arch support.Insole 10 includes a base support shell 50, a liner 100 and a dynamicsupport that is disposed between base support shell 50 and liner 100.FIG. 1 c illustrates insole 10 and dynamic support 150 without liner 100for ease of viewing.

Referring to FIG. 2 and FIG. 3, dynamic support 150 provides support tothe posterior medial arch immediately adjacent to the heel portion 45 ofbase support shell 50. Dynamic support 150 supports a portion of thearch beneath and adjacent to the calcaneus bone. Dynamic support 150 mayalso support a posterior portion of the lateral arch on the outer sideof a foot of a wearer.

FIG. 3 shows a cross-section of dynamic support 150 disposed inside ofbase support shell 50. FIG. 3 shows that dynamic support 150 ispre-contoured with a slight radius 152. Liner (not shown) would besecured to top of dynamic support 150. Dynamic support 150 is disposedin heel portion 45 of base support shell 50. Dynamic support 150 iscompressed by wearer under pressure of weight during ambulation toprovide support and comfort to the heel and support and comfort tolateral and medial arch areas of foot. Accordingly, dynamic support 150must be moldable yet must maintain its shape once it has been molded bythe user during wear.

Dynamic support 150 can be made using various materials. As shown inFIG. 5, dynamic support 150 may include individually movable components,such as particles 160. Particles 160 may include seeds, such as birdseeds, beads, or granules that are solid or hollow and made from wood,polyurethane, polypropylene, polyvinylchloride, polyethylene of fibrous,resilient or solid components. Particles 160 may include a range ofhardnesses to accommodate the support needs of a wearer. When seeds areused, seeds may be large or small size seeds. Large sized and mediumsized seeds have a diameter of from 2 mm to 3 mm and small sized seedshave a diameter of from 1 mm to 2 mm. Dynamic support 150 may be madefrom individually movable components that are fibers or strands insteadof particles. Fibers may be made from resilient materials such asrubber, polystyrene and elastomeric synthetic materials. Dynamic support150 may also have a porous outer surface.

Particles 160 may also include air spheres. Air spheres are made fromresilient materials such as rubber, polystyrene and elastomericsynthetic materials with encapsulated air. Accordingly, such materialsare highly resilient with excellent memory return. Such materials mayhave a flexural modulus of 10,000, a specific gravity of 1.209 and adurometer of 45-50 Shore A. Air spheres preferably have a diameter in arange of from 1.5 mm to 3 mm and are compressible and filled with air.

Particles 160 may be placed in a U-shaped container prior to use foreasy handling as shown in FIG. 4. Particles 160 may be placed in package163 that is not preformed and hence does not have radius like support ofFIG. 3. When package 163 is not preformed, a flexible packaging must beused to permit stretching when package is formed by user. Preformedpackages are particularly effective in a retail setting in which usersmay wish to select the composition and/or hardness of dynamic support150. FIG. 4A shows resilient spacer 153 disposed under dynamic particlesupport 150 in the heel region (not shown). Resilient spacer 153 isapproximately 2 mm thick and is preferably formed of an elastomericmaterial, such as Poron® (e.g. a registered trademark of RogersCorporation pertaining to microcellular urethanes). This spacer 153allows for enhanced cushioning or shock absorbing in the heel region.

Package 163 may be formed by processes such as injection molding, vacuumforming or stamping. Alternatively, package 163 may be formed fromfabrics such as polyester. Package 163 may be secured to base shellsupport 50 by an adhesive. Package 163 may be covered by a coating ofsilicone or other resilient material or medium for additionalcushioning. A spacer 167 may be included between opposite sides ofpackage 163 to maintain position of particles 160 in package basesupport shell 50. Spacer 167 may have of width of approximately 3.18 to6.35 mm and be affixed to lower surface of base shell support. A largerspacer of from 12.9 mm to 25.40 mm may be used to secure a liner, whichcovers particles 160 in package 163, in place. In each of theconfigurations noted above, that are formed by the consumer, thepackaged particles may be coated on the surface with a layer such assilicone, a permeable medium (e.g., screen mesh), polyester fabric, tec.A film of adhesive may be applied to the layer and an additional layerof fabric may be used to cover film of adhesive.

Dynamic support 150 can also be formed by a consumer. Dynamic support150 contains seeds or small particles that may be placed in package 163with a material such as epoxy or polyurethane resin. A catalyst such aswater can be introduced to the contents of dynamic support 150 toactivate the polyurethane for example. Different combinations ofcatalyst may be mixed with the polyurethane. A consumer may placedynamic support 150, polyurethane and water, in a package 163 to beplaced in a shoe for molding during ambulation. Alternatively, package163 may contain a pouch containing the water catalyst that can be openedby a consumer during ambulation. Mixing of the water catalyst with thepolyurethane would activate the polyurethane. The dynamic support 150would be formed during ambulation by the consumer.

Referring to FIG. 5, particles 160 may be mixed with a medium 162 toenhance their ability to maintain a shape during use to maximize supportto wearer of an insole. Medium 162, such as for example, polymersilicone may be used to form dynamic support 150. Dynamic support 150can be made to include different ratios of particles 160 and medium 162to achieve the desired characteristics of dynamic support 150. Byincreasing the proportion of particles 160 relative to silicon forexample, the memory of the silicone is reduced making support component150 softer and more malleable. In other words, a medium 162, such assilicone, makes dynamic support 150 harder after such medium 162 hascured and hardened. Particles 160 may also be wetted with water prior toadding to medium 162 to reduce the memory of the resulting dynamicsupport 150. In addition to silicone, medium 162 may also includematerials such as urethane, EDPM, or foamed materials like ethafoam orneoprene.

In addition combining particles 160 with medium 162, a lubricant 166 maybe added to medium 162 to maintain fluid state of medium 162. Alubricant 166 such as PTFE (polytetrafluoroethylene), prevents thesilicone from curing too readily and fully hardening and also reducesthe recovery in compression or memory of the silicone. In addition toPTFE, other lubricants, such as PTFE grease, grease enhanced with PTFE,liquid polyurethane, ceramic grease and synthetic lubricants such asKrytox®, a registered trademark of DuPont and is a family ofhigh-performance synthetic lubricants (oils and greases) with a varietyof applications. It is a colorless polymer containing etherfunctionality. Krytox oils are fluorocarbon polymers ofpolyhexafluoropropylene oxide, with a chemical formula:

F—(CF(CF₃)—CF₂—O)_(n)—CF₂CF₃

where the degree of polymerization, n, generally lies within the rangeof 10 to 60. These compounds are collectively known by many namesincluding perfluoropolyether (PFPE), perfluoroalkylether (PFAE) andperfluoropolyalkylether (PFPAE). A unique identifier is their CASregistry number, 60164-51-4.

In addition to PFPE, Krytox grease also contains telomers of PTFE and infact was designed as a liquid or grease form of PTFE. It is thermallystable, nonflammable (even in liquid oxygen), and insoluble in water,acids, bases, and most organic solvents. It is nonvolatile and usefulover a broad temperature range of −75 to 350° C. or higher. Its highresistance to ionizing radiation makes it useful for the aerospace andnuclear industries. It can also withstand extreme pressure and highmechanical stress.

The combination of medium 162, such as silicone with lubricant 166 suchas PTFE together with particles 160 can achieve a customized dynamicsupport 150 depending upon the needs of the individual and still offersupport to the heel and arch while still offering resilience and desiredmolding.

Fibers, seeds, or beads, may also be combined with a medium and/or alubricity enhancer to provide the functionality described above withregard to particles 160.

A malleable and softer dynamic support 150 is achieved with a lowerpercentage of medium 162 (silicone) and lubricant 166 (PTFE); whereas aharder dynamic support 150 is achieved with a higher percentage ofmedium 162 (silicone) combined with particles 160. A support member 150with too much resilience from the silicone would not provide thecustomized support to the heel and arch of the wearer by retaining anydeformation during wear. In contrast, dynamic support 150 with too muchPTFE may not have a degree of resilience.

When dynamic support 150 includes particles 160 with lubricant 166,without medium 162, a mesh overlay encourages even distribution of theunderlying beads or fibers in dynamic support 150 as shown in FIG. 18 at253.

When medium and large seeds are mixed a range of from 4% to 20% siliconerelative to the volume of seeds used. A preferred range of silicone is2% to 10% relative to the volume of seeds. Silicone and PTFE can bemixed with medium and large seeds in the following ratios by volume 36%silicone plus 8% PTFE, 11% silicone and 5% PTFE, 5% silicone and 1% PTFEand 16% silicone and 8% PTFE. The working range of silicone is from 32%to 1% PTFE by volume. When PTFE is used alone with medium and largesized seeds, the working range PTFE is from 2% to 12% by volume with apreferred range from 7% to 10%. Organic materials can also be mixed withmedium and large sized seeds. For example, peanut butter and flour maybe used. From 15% to 20% peanut butter plus from 3-5% flour by volumemay be used.

When small seeds are used as the particles, a range of from 100% smallseeds (particles) by volume relative to 5% silicone is used. A preferredrange of 2% to 8% silicone by volume relative to 100% seeds, siliconeand PTFE can be mixed with small seeds in the following ratios byvolume: 22% silicone, plus 8% PTFE, 16% silicone and 5% PTFE. Theworking range of silicone is from 4% to 22% volume and 3% to 8% PTFE byvolume. When PTFE is used with small sized seeds, the working range PTFEis from 2% to 7% by volume with a preferred percentage of 6%. Organicmaterials can also be mixed with small seeds. For example, peanut butterand flour may be used. From 15% to 20% peanut butter plus from 3-5%flour by volume may be used.

Alternatively, the support component 150 can be entirely made frommedium 162 and lubricant 166 or silicone 162 alone. When a combinationof silicone and PTFE are used, a range of 9% to 16% PTFE and from 84% to91% of silicone is used. A range of from 11% to 12% of silicone ispreferred, for support component 150 to retain memory and contour. Whendynamic support 150 includes medium 162 and lubricant 162, suchmaterials can be prepackaged (such as in a package 163) to provide acustom fit.

A dynamic support 150 that is medium 162 alone can also be customized toa user. To specifically fit dynamic support 150 that is entirely medium162, medium 162 must be dispensed into base support shell 50 and coveredwith a liner 100, shown in FIG. 1 b. The user applies the weight ontheir foot and body to the insole to contour the dynamic support to theplantar surface of the foot. After several hours, dynamic support willharden and retain the contour of the foot.

Dynamic support 150 can have a variety of anatomical contours and sizesto adjust to the needs of the user. Dynamic support 150 may be providedin different sizes, narrow, medium and wide, to accommodate heel widthsof differing sizes. For example, dynamic support 150 can be specificallystructured for a child, to aid in excessive pronation or supination.Dynamic support 150 can have a variety of densities depending upon theweight of the user. For example, a 22.68 kg child would have a dynamicsupport 150 having a relatively viscous or low density composition,while a 90.72 kg adult would have a dynamic support 150 of a densercomposition.

Referring to FIG. 6, dynamic support 150 is not only confined to heelportion 45. Dynamic support 150 migrates during wear to support aportion of the lateral and medial arches that are anterior to the heel.Dynamic support 150 migrates to support portions of the medial arch andthe lateral arch that are anterior to the heel and are not supported bycontoured portion 55 or lateral portion 54, respectively of base supportshell 50. Significantly, dynamic support 150 conforms to underside ofmedial arch and lateral arch of the wearer as such support 150 flowsover contoured portion 55 and lateral portion 54 of base support shell50.

Together, dynamic support 150 and base support shell 50 provide supportto the heel of the wearer and to at least one of a lateral arch, amedial arch and a transverse arch. Dynamic support 150 and base supportshell 50 each provide partial support to the arch(es) of the wearer.

Referring to FIG. 7 a detailed drawing of base support shell 50,according to the first embodiment of insole 10 that is taken from medialside, is shown. Referring to FIGS. 6 and 8, a detailed drawing of basesupport shell 50, according to the first embodiment of insole 10, isshown that is taken from the lateral side. Base shell support 50 has anupper surface 15 and a lower surface 20. Base support shell 50 is moldedand structured to support the four arches of the foot, namely, themedial arch, the lateral arch, the metatarsal arch and the transversearch.

Base support shell 50 has a lateral side 25 that corresponds to alateral side and lateral arch of a foot, a medial side 30 thatcorresponds to a medial side and the medial arch of foot, and a sidewall 28. Side wall 28 has a height of approximately an inch toaccommodate dynamic support 150 (not shown). Base support shell 50 hasan anterior portion 35, a heel portion 45 and a middle portion 40between anterior portion 35 and the heel portion 45. Heel portion 45 hasa center heel portion 44.

Base support shell 50 has a contoured portion 55 that provides a partialmedial arch support to the medial arch of the wearer. In particular,contoured portion 55 supports an anterior portion of the medial archproximate the metatarsals of the wearer. Contoured portion 55 is on themedial side 30 of base support shell 50, a part of the anterior portion35 and the middle portion 40 of base support shell 50. Contoured portion55 provides resilient support to an arch of a wearer when force isapplied, flexed and released, during ambulation, for example. Contouredportion 55 is anterior to the of heel portion 45 of base support shell50.

Similarly, base support shell 50 has a contoured portion 54 that thatprovides a partial lateral arch support to the lateral arch of thewearer. In particular, contoured portion 54 supports an anterior portionof the lateral arch proximate the metatarsals of the wearer. Contouredportion 54 is on the lateral side 25 of base support shell 50 and is apart of the anterior portion 35 and the middle portion 40 of basesupport shell 50. Contoured portion 54 provides resilient support to anarch of a wearer when force is applied, flexed and released, duringambulation, for example. Contoured portion 54 is anterior to the of heelportion 45 of base support shell 50.

Dynamic support 150 partially supports both the posterior medial archand posterior lateral arch which together with contoured support 55 and54, provide the support to the medial and lateral arch of the wearer. Bybeing a moldable member, dynamic support 150 is able to provide thedynamic support to the posterior medial arch and posterior lateral archof the wearer. Dynamic support 150 migrates beneath lateral andmetatarsal arches of foot during ambulation. Dynamic support 150migrates in a direction towards contoured portion 54 and 55 of lateraland medial sides of the foot. In this way, base support shell 50 anddynamic support 150 together may provide for support of the entiremedial and lateral arch of the wearer.

Base support shell 50 is preferably vacuum molded, injection molded orstamp molded to a semi-flexible, semi-rigid or rigid shell dependingupon the needs of the user. The degree of rigidity is controlled by thethickness to which base support shell 50 is molded or molded withstiffening enhancing elements. Base support shell 50 is molded usingmaterial such as polyvinylchloride (PVC), polyurethane, polypropylene orother plastic. The thickness of contoured portion 50 is preferably from1 mm to 3 mm.

Base support shell 50 adjusts to the plantar contour of a foot of awearer from downward force after several hours of wear by user.Contouring of base shell support 50 may be hastened by application ofheat.

Base support shell 50 has contoured portion 52 that supports thetransverse arch and contoured portion 53 that supports the metatarsalarch of the wearer. Contoured portion 52 and contoured portion 53 arelocated between contoured portion 55 on medial side and contouredportion 54 on lateral side. The base support shell 50 is structured tosupport all four arches. Significantly, all four arches are molded intobase support shell 50 to support the medial, lateral, metatarsal andtransverse arches of the foot.

Referring to FIG. 9, an additional layer 70 may be affixed to uppersurface of base shell support shell 50. Layer 70 is a thin layer ofmolded material, preferably reinforced with, for example, fiber glass,to provide additional support or strength to base support shell 50. Inuse, layer 70 would be selectively applied to upper surface of basesupport shell 50 for added reinforcement. Alternatively, additionalflexibility could be maintained at contoured portions 54, 55 by formingsuch portions to be thinner in comparison to other portions of basesupport shell 50 to permit a greater degree of resilience in flexion andcustom contouring during ambulation or for greater comfort. If moresupport is needed, base support shell 50 may be molded to have adifferent thickness or to include stiffening geometry. Base supportshell 50 may be injection molded with ribs 53, for example, in thecontoured portions 54, 55 to provide additional structural support. Inparticular, ribs 53 may be molded on the lower surface 20 andselectively placed under contoured portion 54, 55, as shown in FIGS. 10a and 10 d.

FIG. 10 a shows lower surface 20 of base support shell 50. Lower surface20 may have additional support elements 75 and 80. For example, a bottompad 80 is applied to lower bottom surface 20 adjacent to contouredportion 55 to provide additional support. An additional pad 75 isapplied to the lower surface 20 immediately below the transverse arch,metatarsal arch or heel portion 45, for added support. The resilientmaterial of pads 80 and 75 provide support beneath lower surface 20.Pads 80 and 75 provide an upward force on surface 20 due to theresilient material from which pads are constructed. The purpose of thepad 75 and pad 80 are to reinforce the metatarsal arch, the medial archand/or the lateral arch to provide support in addition to supportprovided by base support shell 50.

FIG. 10 b shows a support pad 82 beneath heel portion 45. FIG. 10 cshows that pad 82 may have an asymmetrical configuration depending uponthe needs of the wearer. FIG. 10 d shows supports 75, 80 and 82 affixedto underside of base support shell 50. There may be four pads, such thateach of the four pads is positioned beneath one of the arches to provideadditional support beneath the arch. The pads are removable and may beselectively placed.

Referring to FIG. 11, a further component of insole 10 is liner 250.Liner 250 has an upper surface 255 and a lower surface 260, a heelportion 265 and an anterior portion 263. Liner 250 overlays base supportshell 50 and is longer than the ⅔ length base support shell 50. Uppersurface 255 of liner may optionally be covered with a fabric layer thatis trimmed to fit the length of base support shell. Heel portion 265 isshaped to mate with heel portion 45 of base support shell 50 to containor sandwich dynamic support 150 between liner 250 and base support shell50. Liner 250 includes a contoured portion that overlays contouredportion 55 and 54 of base support shell 50 and dynamic support 150, toeasily conform to contoured portion 55 and 54 and provide a snug fit inthe shoe of the wearer. Liner 250 conforms to support base shell 50 toprovide cushioning to the wearer and to secure particles 160 of supportcomponent within insole 10.

Liner 250 provides cushioning for the heel of the wearer. Liner 250 issecured to base support shell 50, at side walls 28, at center portion 44and at anterior portion 35 of base support shell 50. By being secured atcenter portion 44 of heel, liner 250 ensures that particles 160 ofdynamic support 150 stay in place around perimeter of base support shell50, when dynamic support 150 includes high proportion of particles byvolume. Liner 250 is secured to base support shell 50 by an adhesive,stitches or by snap fittings.

Liner 250 may be injection molded and have regions, such as a heelregion, a medial arch region, a metatarsal arch region, a lateral archregion and a transverse arch region, of varying densities. For example,the heel region may have a soft density, the arch region may have ahigher density than the heel region because it must support a level ofweight of the user. The metatarsal region beneath toes may be soft toaccommodate diabetic users, for example. Alternatively, when liner 250is vacuum formed it has a uniform density throughout its length. Foradditional softness and cushioning effect, materials such as Poron(e.g., a registered trademark of Rogers Corporation may be laminated tobottom surface of liner 250.

An additional layer 252 of a cushioning material such as foam or Poroncould be placed between liner 250 and base shell support 50 in the heelregion 45 to provide an additional layer of cushioning to the heel ofthe wearer. Alternatively, dynamic support 150 can be placed directly onbase support shell 50 and covered with a thin layer of leather, toprovide a cushioning effect as well. When dynamic support 150 is madefrom silicone, such silicone in its non-cured state that is in directcontact with the thin layer of leather acts as an adhesive securing theleather to dynamic support 150.

In FIG. 12 and FIG. 14, second embodiment of insole is shown andreferenced by reference numeral 350. Insole 350 has a base support shell300, a top liner 305 and a dynamic support 310. Dynamic support 310 isdisposed between base support shell 300 and liner 305. Base supportshell 300 is structured to only support the heel of the wearer, and,therefore, includes a heel portion 325. Accordingly, base support shell300 does not have a contoured portion that supports the anterior end ofthe medial arch of the wearer proximate the metatarsals and the flangesof the foot. Dynamic support 310 disposed in heel portion 325 supports aposterior portion of medial arch and lateral arch disposed proximateheel of wearer. Liner 305 has an anatomical heel molded to conform tothe heel portion 325 of base support shell 350. Referring to FIG. 10 c,a medial wedge 82 may be placed under dynamic support 310 or outermedial side. Alternatively, liner 305 can extend the full length of thefoot to which insole 350 is inserted and have a molded contour portionbuilt in. Liner 305 can have an anatomical contour with extra supportivethickness in the arch and metatarsal contour or a ⅔ foot length liner.

Referring to FIG. 13 and FIG. 15, a third embodiment is shown and as afull length insole and is referenced by reference numeral 450. Insole450 includes a base support shell 400, a liner 410 and a dynamic support420. Dynamic support 420 is disposed between base support shell 400 andliner 410. Base support shell 400 is structured to support the entirefoot of the wearer, and includes a heel portion 425, a middle portion430 and an anterior distal portion 435. Accordingly, base support shell400 has a contoured portion 440 that supports the medial arch andlateral arch of the foot of the wearer. Dynamic support 420 disposed inheel portion 425 supports a posterior portion of medial arch and lateralarch disposed proximate heel of wearer. Liner 410 has an anatomical heelmolded to conform to the shape of heel portion 425 of base support shell400. An underside of insole 450 may include support wedges, similar topads 75 and 80 of FIG. 10 a of base support shell 50.

In the third embodiment, a secondary dynamic support may be provided inthe anterior portion of the midsole or insole heel portion 45 of basesupport shell 50, as shown in FIG. 16. Secondary dynamic support 151also comprises particles 160 similar to dynamic support 150, except thatsecondary dynamic support 151 has a shape of a truncated oval to mimicthe topography beneath the toes in the midsole or insole, according tothe present embodiment may also be located to support the anteriorportion of the foot. FIG. 16A depicts yet another embodiment whereinresilient spacer 153 is disposed under dynamic particle support 150 inheel portion 45.

In a further embodiment shown in FIG. 17, the insole 600, in addition tobase support shell 50, liner 250 and dynamic support 150, a furtherlayer 253 overlies particles 160 of dynamic support 150. Layer 253overlies particles 160 to contain such particles in heel portion 45 ofbase support shell 50. Layer 253 may be a permeable medium (e.g., screenmesh), polyester fabric or any such porous layer that may be secured toparticles 160 by a coating 254. When coating 254 is made from a materialsuch as silicone, such silicone penetrates porous layer 253 to bond toparticles 160. By covering particles 160 with layer 253, particles 160are able to migrate beneath the heel and posterior portion of thelateral and medial aches and are prevented from escaping into otherportions of shoe.

The steps of assembling the insole are described below in particular toreference to FIG. 2, 10 a, 17 and FIG. 18. Independent of the embodimentof insole that is being assembled, the steps are identical. Base supportshell 50 is formed using vacuum forming, injection molding or stampingto achieve the desired shape including contoured portions 54, 55, 52, 53as desired.

Base support shell 50 can be adjusted if contoured portion provides toomuch support in the medial or metatarsal arch. The arch may be loweredby directing heat, such as from a heat source towards the arch forapproximately 30 seconds to soften the material. The pressure exerted onbase shell support 50 by the weight of the wearer during ambulation willadjust the arch to the proper height.

On underside 20 of base support shell 50, as shown in FIG. 10 a, pads 75and 80 are selectively placed and secured to provide added support tothe central and medial portions of the base support shell 50 to providesupport and resilience. Pads 75 and 80 can be secured, by an adhesivefor example, to lower surface 20. Pads 75 and 80 can be secured to basesupport shell 50 at any time after base support shell 50 is formed andcured and may be removed by user or wearer.

FIG. 17A shows the resilient spacer 153, which is disposed betweendynamic particle support 150 and the top surface of based support shell50. In particular, both resilient spacer 153 and dynamic particlesupport 150 are disposed in heel portion 45.

Referring to FIG. 18, dynamic support 150 is placed into heel portion 45of base support shell 50. A spacer 88 is secured to the center 44 of theheel portion 45 to prevent migration of dynamic support 150 into thisregion of support base shell 50. Alternatively, spacer 88 could have alonger shape to create a channel to maintain dynamic support 150 inperimeter of heel portion 25. Spacer 88 is placed between arms ofU-shaped dynamic support 150. Spacer 88 is preferably glued to center ofheel portion 45 and has a thickness from 1 mm to 2 mm. Spacer 88 notonly ensures that dynamic support 150 will maintain its positionproximate wall 28 of heel portion 45, but also provides a degree ofsupport under the calcaneus of the wearer. Spacer 88 also ensures thatan adequate volume of dynamic support 150 is disposed proximate sidewall 28 to migrate into space between underside of posterior medial andlateral arches and base support shell 50.

A permeable medium 89 can be used to cover dynamic support 150 to ensurethat the dynamic support 150 and particularly particles 160 of supportcomponent 150 do not migrate from a position between base support shell50 and liner 250, such as shown in FIG. 18. Permeable medium 89 issecured to side wall 28 and to spacer 88 by an adhesive, stitches orsnaps. Permeable medium 89 also provides a degree of shock resistance toheel of wearer because it acts as a hammock to distribute pressure ofheel against sides of dynamic support 150. A layer of silicone forexample may be placed over permeable medium as a coating. Permeablemedium 89 is not required to cover dynamic support 150 when it containssilicone; however, permeable medium 89 provides the force distributionfeature described. When dynamic support 150 includes particles 160alone, permeable medium 89 is placed over such particles 160 to preventmigration or escape of particles 160 from between base support shell 50and liner 250. Permeable medium 89 may covered topped with a layer ofsilicone or Poron. Such layer of silicone is connected or adheres toside wall 28. Silicone layer is allowed to dry over dynamic support 150,for several hours such as 24 hours. The durometer of thin layer ofsilicone is preferably of a low hardness. Such durometer preferably isin the range of from 10-20 hardness is used. This layer of silicone notonly acts to confine particles 160 to heal portion, but also acts as acushioning layer to render support component 150 that includesexclusively particles 160, more resilient and soft. Permeable medium 89or other materials such as polyester fabrics or stretch nylons, are usedwhenever there exists the possibility of particles 160 being released.

Alternatively, silicone coating alone may be applied to surface ofparticles 160 directly when they are placed in heal section 45. Afterdynamic support 150 is placed, liner 250 is preferably placed overdynamic support 150 and secured to spacer 88 and side walls 28 of basesupport shell 50. Spacer 88 provides for adhesive contact to secureliner 250 to base support shell 50 at center 44 of heel portion 45.

Dynamic support 150 may be permitted to cure so that dynamic support 150is hard enough to be handled during manufacturing. After curing, dynamicsupport 150 may be covered with silicone or with a permeable medium 89to prevent any particles from escaping and not compromising the abilityof such blend of particles to migrate. The use of permeable medium 89 isparticularly preferable for an athletic shoe. When dynamic support 150contains PTFE and a lubricant, dynamic support is deformable yetmaintains support beneath heel and lateral and medial arch of wearer.Alternatively, dynamic support 150 can comprise only silicone.

Liner 250 is then placed over base support shell 50 and dynamic support150 is secured in place. Liner 250 may optionally be placed over andsecured over permeable medium 89 and silicone layer if such componentsare used. Liner 250 is preferably placed over dynamic component 150after hardening. Liner 250 ensures that support component 150 will notmigrate from its position between liner 250 and base support shell 50.Yet, liner 250 permits dynamic support to migrate between base supportshell 250 and liner 250 to provide support in region of medial arch andlateral arch.

FIG. 19 shows a midsole 500 having dynamic support 510 and base supportshell 50 built into a shoe 501. Midsole 500 is actually built in to thestructure of shoe 501 during the manufacturing process. Base supportshell 50 is a premade base shell with built-in anatomical contours,specifically medial, lateral, metatarsal and transverse arches, areprovided. Dynamic support 510 as discussed previously is also placedinto midsole 500 during manufacturing process with a top liner 515.

In an alternative embodiment, midsole 500 can have a length ofapproximately two-thirds the length of shoe 501 and have a built incontour portion 520. Midsole 500 also comprises a dynamic support 510 inregion supporting the heel or arch of the wearer. Dynamic support 510 issupported by sidewalls of the shoe. In this embodiment, dynamic support510 is covered with a material 530 such as leather, towards the end ofthe shoe. Built in contour portion 520 provides partial medial arch andlateral arch support, as in the earlier embodiments of the presentdisclosure. Dynamic support 510 may be removed from shoe 501 or replaceddepending upon the needs of the wearer.

FIG. 19 also shows midsole 500 having a secondary dynamic support 513located at ball and toe region of the foot. In this embodiment, aflexible permeable medium 515 covers and retains secondary dynamicsupport 513 in position. Additionally, the particles could also migratewithin the forward metatarsal region to provide a supportive custom fit.

FIG. 20 a shows a medial side of a foot of athletic shoe 600 that has amidsole 605, and a base sole 610 that is injection molded (portionsremoved for clarity). Base sole 610 has an outer top surface 615, ananatomical contour 620, a heel region 625 and a top liner 618. Midsole605 also has a sole covering 630 and a shoe sole 635. A dynamic support650 having a substantially u-shaped configuration with particles isplaced into heel region 625 during manufacturing. Dynamic support 650 isfixedly secured to heel region 625 and by an adhesive.

FIG. 20 b shows a cross-section of midsole 605. Midsole 605 also shows aspacer 655 that is placed between top liner 618 and base sole 610.Spacer 655 maintains position of dynamic support 650 at sides of heelregion 625.

FIGS. 21 a through 21 c illustrate a dynamic support 150, and basesupport shell 950 that is incorporated into a boot or brace 900. Basesupport shell 950 is either a ⅔ or full length component. Brace 900 hasa hinge 903 with a flange 904 that connects upper boot 905 to lower boot910. Dynamic support 150 and base shell support 950 together provide thecombined lateral and medial support the lateral and medial arches of thewearer, as described in earlier embodiments. Dynamic support 150migrates during wear to support a portion of the lateral arch, medial,metatarsal or transverse arch.

Although the present disclosure describes in detail certain embodiments,it is understood that variations and modifications exist known to thoseskilled in the art that are within the disclosure. Accordingly, thepresent disclosure is intended to encompass all such alternatives,modifications and variations that are within the scope of the disclosureas set forth in the disclosure.

What is claimed is:
 1. A support for an article of foot wear comprisinga dynamic support that is capable of molding to a portion of a plantarsurface of a foot, wherein said dynamic support comprises a plurality ofindependently movable particles.
 2. The support according to claim 1,wherein said plurality of independent movable particles are suspended inat least one material selected from the group consisting of: fluidmaterials, lubricity enhancers, and catalysable polymers.
 3. The supportaccording to claim 1, wherein said plurality of independently movableparticles are selected from the group consisting of: seeds, air spheres,polyurethane particles, polypropylene particles, polyvinylchlorideparticles, polyethylene particles, resilient rubber particles, solidparticles, granules, fibers and strands.
 4. The support according toclaim 2, wherein said fluid material is a highly viscous fluid materialcomprising silicone.
 5. The support according to claim 2, wherein saidlubricity enhancer is at least one material selected from the groupconsisting of: polytetrafluoroethylene (PTFE) and grease.
 6. The supportaccording to claim 1, wherein said dynamic support exhibits a shapeselected from the group consisting of: a substantially U-shaped member,a substantially torus-shaped member and a substantially ovoid shapedmember.
 7. The support according claim 1, further comprising: a basesupport shell having a heel portion, wherein said dynamic support isdisposed on and supported by said base support shell.
 8. The supportaccording to claim 7, wherein said base support shell is a molded membercomprising a flat portion, a curved wall that surrounds said flatportion to form said heel portion, and two or more contoured portionsdisposed on opposite sides of said flat portion.
 9. The supportaccording to claim 8, wherein said contoured portions comprise a medialarch support portion disposed on one side of said flat portion and alateral arch support portion disposed on an opposite side of said flatportion.
 10. The support according to claim 7, wherein said base supportshell is a flexible component that supports said dynamic support. 11.The support of claim 7, wherein said base support shell is a moldablemember that comprises a thermoplastic polymer.
 12. The support of claim11, wherein said thermoplastic polymer is selected from the groupconsisting of: polyvinylchloride (PVC), polyurethane, polypropylene,polyethylene or plastic.
 13. The support according to claim 1, furthercomprising: a built-in portion of a shoe; and liner that covers saidbuilt-in portion of a shoe; wherein said dynamic support is disposedbetween said built-in portion of the shoe and said liner that conformsto a portion of said built-in portion of a shoe and to the plantarsurface of the foot of a wearer to support at least one arch of the footof the wearer during wear.
 14. The support of claim 13, wherein saidliner comprises a compliant medium.
 15. The support according to claim1, further comprising a permeable medium disposed about saidindependently movable particles.
 16. The support according to claim 7,further comprising a resilient spacer disposed between said base supportshell and said dynamic support in said heel portion.
 17. The supportaccording to claim 13, further comprising a resilient spacer disposedbetween said built-in portion of the shoe and said dynamic support. 18.A support for an article of foot wear comprising: a dynamic support thatis capable of molding a portion of a plantar surface of a foot, whereinsaid dynamic support comprises a substantially U-shaped member andeither a gas or a fluid disposed therein.